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09 July 2020

TOP 6 challenges of oil, gas & mining industries: how to solve them?

What challenges is the mining industry facing? How to set up fuel control for mining equipment and provide safety of minerals transportation? How to receive regular data of pumping equipment operation even in remote areas? How to choose a reliable monitoring solution outside the GSM network? In this article, we highlight the most priority challenges of the mining industries and advise on what equipment can be used to solve them.

1. Fuel volumes control in oilfield equipment

The effect of fuel economy on industrial equipment is much more noticeable when compared with personal vehicle monitoring. Economic efficiency and productivity of the enterprise depend on sustainable telematics solutions. Especially when 2000 hp engines consume 500 liters of fuel per hour and volumes of unaccounted fuel are measured in tons. 

Due to the big amount of inputs on Galileosky devices, it is possible to set comprehensive fuel monitoring by connecting to equipment default sensors, as well as to external peripherals. Moreover, you can output data to one device via absolutely different interfaces. There are many flow meters and FLSs that couple with the device very well and the nature of settings is clear and easy-to-understand.

2. Chemicals accounting

In addition to fuel control, industrial organizations also need to monitor other parameters that are involved in the process. For example, when the oil recovery of the well falls, the technology of hydraulic fracturing is used to extend its service life. The chemical mixture is pumped into the well under high pressure and breaks the rock from the inside, providing a lighter oil flow. The problem is that the mixture volume supplied to the well is fixed according to normal stats, however, the real volume can be significantly larger, and then the organization may receive less in payment.

With connected units to the equipment sensors of the pumping equipment, heads of the organization can see pressure and quantity data of the supplied mixture. This allows to calculate the piecework wages correctly and keep accurate records of work done. There is one of the most striking examples when monitoring fuel and account of the chemical mixture volumes brought the oilfield services company savings of 250.000$ for six months.

3. Fuel depots monitoring and setting up of autonomous power sources

Oilfield service companies use tanks located on a deserted territory, far from roads and infrastructure, as one of the ways to store fuel. There is not even access to power sources at such facilities not to mention that tanks themselves are not equipped with FLS.

Thus, the creation of an autonomous power supply system from solar panels will help to resolve the issue of electricity, and a special fuel level sensor will provide monitoring of distributed fuel and the ability to maintain a database.

If the monitoring object is located in the northern regions, where there are often low temperatures, then gel batteries can be used. They do not lose capacity in the cold. The circuit which consists of solar panel and gel battery will power the unit and the FLS. As a result, it will be possible to exclude fuel drains, calculation errors, and high costs of covering losses.

4. Recording an accident outside the GSM

In the fields, located in remote areas mining companies can't connect to GSM services. What can be chosen besides Iridium? Which technology will require less data transfer costs and work as reliable as Iridium?

For example, those who mine coal, in addition to controlling the volume of cargo transported, also need to record data on accidents that occur outside the GSM coverage. Indeed, knockings of loaded dump trucks over are a fairly common occurrence, it is simply necessary to track and respond to those accidents promptly.

With Galileosky equipment, a company will be able to record all the accident data, even outside the GSM coverage area. Even after the evacuation and equipment delivery to the GSM zone, owners will know the exact data of the knocking over circumstances, including who was driving at that moment. Based on experience, we can say that Galileosky devices retain all equipment parameters even in the absence of connection.

5. Monitoring of mining equipment with a constant lack of connection

One more urgent task in the mining sector is the monitoring of heavy equipment which never leaves the quarry and does not go into the GSM zone. Bulldozers, excavators and large-capacity dump trucks constantly operate in a coal mine burning a huge fuel amount. Because of the operating conditions and difficult terrain, there is a great risk of equipment failure.

Therefore, to configure the monitoring of heavy mining equipment, Base Block Wi-Fi Hub tracking device is ideal. FLS will continuously record data on refueling, consumption and fuel theft. Galileosky unit will save data from the FLS, and the equipment itself, to the internal memory. Next, refueller or any other machine that regularly appears in the GSM area will collect data from other units where there is no GSM coverage and transmit data to the monitoring server after returning to the base. The result is a comprehensive solution that allows to configure advanced equipment monitoring.

6. Drainage control and pumping equipment remote configuration 

In addition to controlling the equipment, it is important to monitor and remotely configure stationary equipment. For example, pumps that pipe water out of flooding quarries.

If you do not find out that the pump is out of order, the quarry can be flooded, especially during the flood season. Moreover, it is important to know the exact water flow rate for complying with government regulations and reporting.

Galileosky unit in conjunction with flowmeters perfectly suits to solve this task. Additionally, using Easy Logic technology, you can configure the reaction to the event and conditions for its implementation. Also, you can warn dispatchers and persons in charge of maintenance in case of urgent situations. This will protect the company from emergency situations, which could be dangerous and threaten with large fines.

Accurate data is a guarantee of success in mining and oilfield services companies. Today, the key to effective planning and organizing profitable activities is the continuous receipt of actual information about current processes. Thanks to the complex solutions, you can configure continuous monitoring of machinery and equipment, as well as ensure security even at the most remote sites. Change potentially dangerous routes at any time, adjust fuel usage, and improve employee safety.

Want to know what tasks are crucial in other industries and how they could be solved? Get even more knowledge about the capabilities of Galileosky units and Easy Logic technology. Contact your manager or send an email to sales@7gis.ru